2. Metalworking Machines

Question 1

What are the potential health hazards associated with the production of molten metals?

Answer 1

Inhalation of gases/vapours/particulates.

Exposure to intense heat or infrared radiation.

Exposure to excessive noise.

Question 2

Why are housekeeping and personal sanitation critical in workplaces handling molten metals?

Answer 2

Fumes and particulates are often formed when working with molten metals. These can contaminate workers and their clothing.
Contaminants can be taken to other areas of the workplace and to the workers home causing a health hazard.

Question 3

What is forging?

Answer 3

The process of heating a metal close to its melting point and then forming it into shapes by:
Pounding (hammering)
Pressing (presses)
Squeezing (upsetters)

Question 4

List some hazards associated with forging.

Answer 4

Hot surfaces
Hot metal slag
Metal fumes
Hazardous gasses
Crushing
Pinch points
Noise

Question 5

Give examples of guards and safety devices used to safeguard forging hammers.

Answer 5

Guards:
-Light curtains

Devices

• Two-handed controls
• Interlocked gates
• Pressure-sensitive matting for emergency stop

Question 6

What are the 5 common metalworking processes?

Answer 6

Turning
-metal turned against a tool. Example, turning a rod into a screw

Boring
-drill

Milling
-a rotary device used to remove material from the product, creating smooth and/or flat surfaces

Planing
-cuts the surface to produce a large smooth area

Grinding
-abrasives used to shape and finish products.

Question 7

What is an engine lathe?

Answer 7

aka: bench lathe or lathe.

Small to medium-sized horizontal lathe with a carriage and slide.

Question 8

What is a turret lathe?

Answer 8

A turret lathe can hold multiple tools and quickly/automatically switch between tools without needing to remove a tool before adding another.

Question 8

What is a turret lathe?

Answer 8

A turret lathe can hold multiple tools and quickly/automatically switch between tools without needing to remove a tool before adding another.

Question 9

What is a drill press?

Answer 9

A stationary drilling machine. Precise angles, distances, and controlled pressure.

Question 10

What is a metal cutting bandsaw?

Answer 10

A bandsaw is a springy, circular saw that wraps around two wheels. The wheels turn the saw to create the cutting force.
This can be used for straight or curved cuts, like a jigsaw.

Question 11

What is a surface grinder?

Answer 11

A grinding wheel that removes the top layer off a surface to smooth a surface and reduce thickness.

Question 12

What is a horizontal milling machine?

Answer 12

A machine that attaches tools to a horizontal rotor, to cut/drill a product.

Question 13

What is a horizontal milling machine?

Answer 13

A machine that attaches tools to a horizontal rotor, to cut/drill a product.

Uses a metal cutter that moves perpendicular to its axis.

Question 14

What standards cover most machine tools?

Answer 14

ANSI standards.

B11.6 & B11.8

Question 15

List four types of cold forming metal working tools, and identify safety hazards with each.

Answer 15

Standard power press

• crushing
• pinch points

Powered press brake

• crushing
• pinch points

Manual bending brake

• cutting
• shearing
• crushing

Powered metal shear

• cutting
• shearing

Question 16

List safeguards and controls utilized in cold forming machines.

Answer 16

Power press clutch/brake controls

Light curtains (presence sensing device)

Two-hand control activation

Sliding barrier devices

Pull outs

Restraints

Safety mats

Area/perimeter guarding devices

Question 17

Compare and contrast a basic forging hammer and a basic forging press.

Answer 17

Both are large, powerful machines that change the form of metal that has been heated to a near melting point. Usually to create simple shapes, such as a bar or plate.

The hammer pounds the metal directly, or via a die. A forge press squeezes the hot metal into a die.

Question 18

What are the two basic operating steps of a foundry?

Answer 18

1, Production of a mould that will produce the shape of a metal object.

2, Filling of the mould with liquid metal (casting).

Question 19

List the 5 basic metal working processes and identify a common machine tool that performs each.

Answer 19

Turning - Engine lathe

Bore - Metal drill press

Mill - Metal milling machine

Plane - Metal planing machine

Grind - Surface grinder

Question 20

List critical safety hazards associated with metal drill presses and hazard controls that are commonly used to reduce risk.

Answer 20

Puncturing, cutting, entanglement.

Emergency stop button, guard/shield/barrier.

Question 21

List critical safety hazards associated with engine lathes and hazard controls that are commonly used to reduce risk.

Answer 21

Entanglement, pinching, shearing.

Remove loose clothing prior to use, do not place hands on work turning in the lathe.

Question 22

List critical safety hazards associated with mills and hazard controls that are commonly used to reduce risk.

Answer 22

Abrasion, entanglement.

Remove loose clothing prior to use, do not place hands in work area of machine.

Question 23

Discuss metalworking machine design standards and OHS regulations in Canada.

Answer 23

There are ANSI and CSA design standards for metalworking machines.

OHS regulation makes some mandatory, and others are voluntary. To meet due diligence, the voluntary standards must usually be met.

Question 24

List critical safety hazards associated with plate bending rolls.

Answer 24

Crushing, entanglement.

Question 25

List critical safety hazards associated with powered press brakes.

Answer 25

Crushing, cutting.

Question 26

List critical safety hazards associated with powered metal shears.

Answer 26

Cutting.

Question 27

What does CNC stand for?

Answer 27

Computer Numeric Control.